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Evidence Guide: PMBPREP305 - Change extrusion die and setup

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

PMBPREP305 - Change extrusion die and setup

What evidence can you provide to prove your understanding of each of the following citeria?

Prepare to change dies or cores

  1. Plan process for closing down machinery and inform relevant personnel
  2. Take last-off samples as required for die reports
  3. Select dies or cores to match product/process specification
  4. Implement measures to control identified hazards in line with procedures and duty of care
Plan process for closing down machinery and inform relevant personnel

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Take last-off samples as required for die reports

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Select dies or cores to match product/process specification

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Implement measures to control identified hazards in line with procedures and duty of care

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Shut down extruder

  1. Stop downstream equipment
  2. Stop feed, drop temperatures, stop vacuum pump and purge the extruder
  3. Activate isolating locks, disconnect power to heaters
Stop downstream equipment

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Stop feed, drop temperatures, stop vacuum pump and purge the extruder

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Activate isolating locks, disconnect power to heaters

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Change set-up

  1. Remove, clean and store die according to workplace procedures
  2. Fit replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification
  3. Remove and re-fit calibrator sleeve and seals as required
  4. Set heats according to pre-start procedures
Remove, clean and store die according to workplace procedures

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Fit replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Remove and re-fit calibrator sleeve and seals as required

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Set heats according to pre-start procedures

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Restart and test-run the new set-up

  1. Check operation of die against product quality
  2. Compare machine setting ranges against documented requirements
  3. Check the first-off sample for required standards
  4. Fine-tune settings and other production variables as required
  5. Note variances between standard operating procedures (SOPs) and actual production run
  6. Complete workplace documentation and report to appropriate personnel
Check operation of die against product quality

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Compare machine setting ranges against documented requirements

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Check the first-off sample for required standards

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Fine-tune settings and other production variables as required

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Note variances between standard operating procedures (SOPs) and actual production run

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Complete workplace documentation and report to appropriate personnel

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Anticipate and solve problems

  1. Recognise a problem or a potential problem
  2. Determine problems needing priority action
  3. Refer problems outside area of responsibility to appropriate person, with possible causes
  4. Seek information and assistance as required to solve problems
  5. Solve problems within area of responsibility
  6. Follow through items initiated until final resolution has occurred
Recognise a problem or a potential problem

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Determine problems needing priority action

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Refer problems outside area of responsibility to appropriate person, with possible causes

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Seek information and assistance as required to solve problems

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Solve problems within area of responsibility

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Follow through items initiated until final resolution has occurred

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare to change dies or cores

1.1

Plan process for closing down machinery and inform relevant personnel

1.2

Take last-off samples as required for die reports

1.3

Select dies or cores to match product/process specification

1.4

Implement measures to control identified hazards in line with procedures and duty of care

2

Shut down extruder

2.1

Stop downstream equipment

2.2

Stop feed, drop temperatures, stop vacuum pump and purge the extruder

2.3

Activate isolating locks, disconnect power to heaters

3

Change set-up

3.1

Remove, clean and store die according to workplace procedures

3.2

Fit replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification

3.3

Remove and re-fit calibrator sleeve and seals as required

3.4

Set heats according to pre-start procedures

4

Restart and test-run the new set-up

4.1

Check operation of die against product quality

4.2

Compare machine setting ranges against documented requirements

4.3

Check the first-off sample for required standards

4.4

Fine-tune settings and other production variables as required

4.5

Note variances between standard operating procedures (SOPs) and actual production run

4.6

Complete workplace documentation and report to appropriate personnel

5

Anticipate and solve problems

5.1

Recognise a problem or a potential problem

5.2

Determine problems needing priority action

5.3

Refer problems outside area of responsibility to appropriate person, with possible causes

5.4

Seek information and assistance as required to solve problems

5.5

Solve problems within area of responsibility

5.6

Follow through items initiated until final resolution has occurred

Required Skills and Knowledge

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare to change dies or cores

1.1

Plan process for closing down machinery and inform relevant personnel

1.2

Take last-off samples as required for die reports

1.3

Select dies or cores to match product/process specification

1.4

Implement measures to control identified hazards in line with procedures and duty of care

2

Shut down extruder

2.1

Stop downstream equipment

2.2

Stop feed, drop temperatures, stop vacuum pump and purge the extruder

2.3

Activate isolating locks, disconnect power to heaters

3

Change set-up

3.1

Remove, clean and store die according to workplace procedures

3.2

Fit replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification

3.3

Remove and re-fit calibrator sleeve and seals as required

3.4

Set heats according to pre-start procedures

4

Restart and test-run the new set-up

4.1

Check operation of die against product quality

4.2

Compare machine setting ranges against documented requirements

4.3

Check the first-off sample for required standards

4.4

Fine-tune settings and other production variables as required

4.5

Note variances between standard operating procedures (SOPs) and actual production run

4.6

Complete workplace documentation and report to appropriate personnel

5

Anticipate and solve problems

5.1

Recognise a problem or a potential problem

5.2

Determine problems needing priority action

5.3

Refer problems outside area of responsibility to appropriate person, with possible causes

5.4

Seek information and assistance as required to solve problems

5.5

Solve problems within area of responsibility

5.6

Follow through items initiated until final resolution has occurred

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret procedures and job specifications

plan and perform shutdown procedures for extruder and downstream equipment

remove, clean and store die according to procedures

select dies, calibration sleeves, seals and tools and install replacement die to meet specifications

set machine conditions for new die

check the installation and operation of new die to identify conformance and/or non-conformance to specifications

make adjustments to settings and equipment operation to rectify variations in equipment operation or product quality

identify hazards and apply relevant hazard controls

distinguish between causes of problems/alarm/fault indications, such as:

operational problems

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

equipment design deficiencies

product parameters (temperature, flows, pressure and levels)

resolve non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to fulfil their job role, including knowledge of:

function and principles of operation of extrusion equipment

methods of connecting extrusion dies to machines

extruder and ancillary equipment shut down processes

impact of incorrect or faulty fitting

the function of each machine setting and the appropriate ranges of settings for specific dies

factors which may affect product quality or production output and appropriate remedies

routine and non-routine problems that may arise, the range of possible causes and appropriate actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used.

Applicable legislation, regulations, standards and codes of practice include:

health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, manual handling and hazardous materials

Australian/international standards relevant to the materials being used and products being made

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of:

emergency procedures

work instructions

SOPs

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Tools and equipment

Tools and equipment include one or more of:

hand carts and trolleys

hoists/lifting equipment not requiring any special permits or licences

basic hand tools

hand tools

relevant personal protective equipment (PPE).

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

weight, shape, volume of materials to be handled

hazardous products and materials

hot surfaces

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

heat, smoke, dust, vapours or other atmospheric hazards

electricity

gas

gases and liquids under pressure

structural hazards

equipment failures

machinery, equipment, product mass

other hazards that might arise

Non-routine problems

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person.

Non-routine problems are unexpected problems or variations of previous problems and include one or more of:

corrosion of die surface

inadequate fitting

faulty components

machine malfunction

variation in product.

Operational knowledge includes one or more of:

procedures

training

technical information such as journals, engineering specifications

remembered experience

relevant knowledge obtained from appropriate people.